Apparatus for making retractile cordage continuously



April 3, 1951 w. 1.. AMES APPARATUS FOR MAKING RETRACTILE CORDAGE CONTINUOUSLY 3 Sheets-Sheet 1 Filed Oct. 23, 1947 INVENTOR WL. AMES A 7' TORNE V Apnl 3, 1951 w. L. AMES APPARATUS FOR MAKING RETRACTILE CORDAGE CONTINUOUSLY 3 Sheets-Sheet 2 Filed Oct. 25, 1947 A TTORNEY April 3, 1951 w. L. AMES APPARATUS FOR MAKING RETRACTILE CORDAGE CONTINUOUSLY 3 Sheets-Sheet 5 Filed Oct. 23, 1947 INVENTOR W.L. AMES By & ATTORNEY Patented Apr. 3, 1951 UNITED STATES: PATENT OFFICE APPARATUS FOR MAKiNG RETRACTILE CORDAGE CONTINUOUSLY William L. Ames, Middle River, Md., assignor to Western Electric Company; Incorporated, New York, N. Y., a corporation of New York 7 Application October 23, 1947, Serial No. 781,734

This invention relates to apparatus for making retractile cordage continuously.

In the past, retractile electrical cords of a type having plastic elements therein have been made'by winding the intermediate portions of the individual cord lengths between the end portions thereof into helices upon relatively short mandrels'and heating the individual cords mounted on the mandrels to soften the plastic elements of the portions of the cords in helical forms so that these intermediate portions of the elements are set in such helical forms when they are cooled and the end portions are set substantially straight, or by winding long lengths of such cord age continuously upon a rigid mandrel and pushing the cordage along the mandrel as it is wound therein. Obviously, the method of winding the cord lengths on short mandrels to form individual cords requires much manual handling of the cord lengths and the mandrels. When the cordage is wound continuously upon a mandrel and is set in the form of a continuous helix and cut into cord lengths, the end portions of such cord lengths must be straightened for the nor mal uses of such cords.

' An objectof the invention is to provide new and s improved apparatus for making retractile cordage continuously.

Another object of the invention is to provide apparatus for continuously forming continuous cordage in a series of interconnected cordlength helices on a mandrel, for setting the cordage in such form and for continuously unwinding the cordage from the mandrel after the cordage has been set in such form.

An apparatus illustrating certain features of the invention, and by means of which methods 13 Claims.

2 Fig.4 is an enlarged, vertical section of an-' other portion of the apparatus;

Fig. 5 is an enlarged, fragmentary, vertical section taken along line 55 of Fig. 4, and

. Fig. 6 is an enlarged, fragmentary, perspective view of a cordage prying shoe forming a portion of the apparatus. Referring now in detail to the drawings, cordage l0 includes a plurality of conductors II-H (Fig. 3) having insulating coverings I2I2 thereon and a jacket I3 enclosing the covered conductors Ii-l I. The jacket I 3 is composed of a compound including rubber, synthetic rubber-like material or other material which may be set in any particular shape by heating the material and thencooling it. The coverings l2-|2 also. may be made of a material which may be set by heating and cooling it. The cordage I0 is servedupon an endless, flexible mandrel I4 by a coiler l5 in the form of sharply curved helices l6l 6 separated by slightly curved helices I'Il I as the mandrel I4 is advanced continuously at a predetermined rate of speed through the coiler I5. The mandrel I4 is advanced through the coiler l5, then through a heating oven 20 and finally through an uncoiler 2| by a grooved advanced around the sprocket 22 to and around a embodying features of the invention may be pracment thereof, when read in conjunction with the appended drawings, in which: Fig. l is a fragmentary, front elevation of an apparatus forming one embodiment of the invention;

t Fig. 2 is an enlarged, fragmentary vertical section of a portion of the apparatus;

.Fig'. 3 is an enlarged, vertical section taken along line 3-3 of Fig. 2;

apart.

grooved guide sprocket 25 and back to the coiler 5. The general features of the coiler, the oven,

the uncoilerand the mandrel are disclosed and claimed in copending application Serial No. 781,735 filed October 23,1947, by T. K. Cox for Methods of and Apparatus for Continuously Making Retractile Cordage.

Straightening discs 25-46 are fixed to the flexible mandrel Id at points thereon equal distances The discs 26-,-26 mesh with notches 212fi in the sprocket 22 and notches 28-28 in V the sprocket 25. The straightening discs have a much larger diameter than that of the mandrel Hi so that each portion of the cordage extending from one side of one of the discs to the other side thereof has two substantially straight portions.

The coiler l5 includes a frame 30 (Fig. 2) having aligned hollow arbors 3| and 32, which are mounted rotatably in bearings 33 and 34, respectively. Non-rotating bell-mouthed guide sleeves 36 and 37 extending through arbors SI and 32, respectively, facilitate entrance of the discs 2526 into the guide sleeves. The internal diameter of the major portion of the sleeve 36 is slightly greater than that of the discs so that the discs may slide tlierethrough. The internal diameter of the major portion of the sleeve 31 is slightly greater than the sum of the diameter of the discs plus the diameter of the cordage l6. Springpressed, forked guides 3838 carried by and revolved with the frame 30 hold the mandrel against lateral deflection as the cordage is wound thereon.

The guides 3838 are urged against stops 3939. As one of the discs 26-26 is advanced against one of the forked guides, the disc pivots that guide out of its path. After the disc clears the spring-pressed guide, the guide springs back against the mandrel M. The guides 38-38 are spaced sufficiently far apart to permit the discs to move only one of the guides from the mandrel at any time. However, each of the guides 98-38 is spaced sufficiently close to the point of application of the cordage to the mandrel to. prevent the pull of the cordage on the mandrel, from deflecting the mandrel laterally.

A gear 35 fastened rigidly to the arbor 3| and driven from a suitable source of power (not shown) serves to rotate the frame 30 around the flexible mandrel I4 and over the straightening discs 2525, which are advanced through the sleeves 35 and 31 and past the guides 3B33. A supply of the cordage I9. is, carried by a supply reel 4c mounted on the frame 36, and the cordage withdrawn from the reel 40 is served helically around the moving mandrel. The cordage is wound in close, small-diameter helices upon the portions of the mandrel |4 between the discs 2626 and is wound over each of the discs 2526; in two substantially straight portions.

The reel 40 is mounted rotatably by arbors 4| and 42 carried by a frame 45, which is secured to and rotated by a shaft 44 projecting therefrom. A leaf spring brake 46 tensions the carriage somewhat so that the cordage is served tightly upon the mandrel l4 and over the straightening discs 26-46. The shaft 44 is mounted rotatably in a thrust bearing 45 carried by the housing 30, and a bevelled gear 50 is keyed thereto. The gear 50 is driven through a bevelled gear 5|, a shaft 52 mounted on bearings 53-53 carried by the housing 30, a bevelled gear 54 and a bevelled gear 55. The bevelled gear 55 is driven through 'a shaft 56 mounted rotatably in bearings 57 and 58 carried by the housing 30, a reversible differential 59, a shaft 99, a suitable adjustable gear box 6|, a shaft 62, a bevelled gear 63 and a fixed bevelled gear 64. This revolves the reel 4|) around an axis perpendicular to the axis of the flexible mandrel l4 so that the cordage In is twisted about its longitudinal axis as it is formed into the helices on the mandrel.

This twisting increases the closeness with which the individual turns of continuous cordage are placed on the flexible mandrel M. The reel 40 is rotated around the axis of the shaft 44 at a predetermined rate with respect to the rate of twist tends to make the helices tighter than they would be otherwise. If it should be desired to make the helices looser, the direction in which the reel would be rotated around the axis of the shaft 64 would be reversed.

The corda e lu coiled into a series of helices travels with the mandrel l4 into and through the oven 20, which heats the jacket l3 and the coverings I2-|2 of insulating material to soften them in the form which they occupy in the helices in which the cordage is coiled. ihe oven 29 is heated by steam from a steam pipe 62 and the exhausted steam is led therefrom by a drain pipe 63' leading to a steam trap (not shown). The oven softens the jacket and the coverings sufficientiy to relieve the strain therein so that the jacket and the coverings set in the forms they occupy in the series of helices when they are cooled.

The coiled cordage and the mandrel l4 pass from the oven 25 to and into the uncoiler 2| (Fig. 4) and the jacket l3 and coverings |2-|2 coolsufficiently to set before they reach the uncoiler. The uncoiler includes a frame l0 having hollow arbors H and 12 projecting therefrom and mounted rotatably in bearings 33 and T4, respectiveiy. Non-rotating guide sleeves l6 and H extend through the hollow arbors l2 and H, respectively, and are identical in construction and function with the guide sleeves 36 and 31 (Fig. 2), respectively.

A gear 80 (Fig. 4) fastened to the arbor H is driven by suitable means (not shown) in synchronization with the gear (Fig. 2) to rotate the frame 19 around the axis of the mandrel |4 revolution of the reel 40 around the flexible manupon the flexible mandrel is uniform regardless of the rate of revolution of the housing 30. This at the same rate and in the same direction as that at which the frame 30 is rotated there around. A shaft 8| is mounted in bearings 82 5 82 carried by the frame 79, and the shaft 8| has a bevelled gear 83 keyed thereto, which meshes with a stationary bevelled gear 84, and, as the frame 70 is revolved about the mandrel, the gears 83 and 84 cause the shaft 8|, to rotate. Rotation of the shaft 8| rotates a shaft 86 mounted in bearings 8l8'|, which are carried on the periphery of the frame 10, through bevelled gears 90 and 9|. A bevelled gear 92 secured to the shaft 86 rotates a bevelled gear 93 to rotate a reel-supporting frame 94 carried by a shaft 95 to which the bevelled gear 93 is keyed. The shaft 95 is rotatably mounted in a radial and thrust bearing 96 secured to the frame ll).

A bevelled gear I09 is rigidly secured to the bearing 95 so that, as the reel-supporting frame 94 is rotated, a bevelled gear lol, which is keyed to a shaft I02 supported rotatably in bearings |03|)3 carried by the reel-supporting frame 94, is rotated. This rotates, through bevelled gears I96 and I91, a shaft I04 supported by bearings |e5--| 95. The shaft H14 rotates a driving disc H0 splined thereto, which drives a reelsupporti'ng arbor through a driven disc 2 The reel-supporting arbor is mounted rotatably and is held against longitudinal movement by a support H3- caried by the frame 94, and, with an adjustable arbor ||4 carried by a support l5, serves to hold a takeup reel H6.

When the arbor is rotated through the discs H0 and H2, it rotates the takeup reel H6 in a clockwise direction, as viewed in Fig. 5, to wind the coiled cordage ||l. upon the takeup reel- A feeler I20 (Fig. 5) biased against the cordage on the. reel ||Bby a tension spring |2| controls the position of the disc ||ll through a linkage. [22' in accordance with the amount of the cordage l0 which has been wound upon the takeup reel so that the speed of rotation of the takeup reel H6 is always just sufficient to prevent slack between the takeup reel and a cordage feeder I23.

The cordage feeder I23 includes a pair of presser belts I24 and I25 (Fig. 4). The presser belt I24 ismounted on idler pulleys I26 and I2'I, while the presser belt I25 is mounted upon an idler pulley I28 and a drive pulley I29. The pulleys I26, 'I2'I, I28 and I29 are mounted upon shafts I3I, I32, I33 and I34, respectively, secured to a tongue I39 formed on the frame 94. The shaft I34 is driven in synchronization with the reel II6 by the shaft I94 through bevelled gears I35 and I36, a shaft I31, adrive pulley I38, a belt I39 and a driven pulley I40 secured to the shaft I34. The feeder I23 advances the coiled cordage I to the takeup reel at a uniform rate of speed, whichrate is the same as that at which the coiled cordage I9 is uncoiled from the mandrel I4. Adistributor I59 positioned between the reel H6 and the feeder I23 includes a guide fork-II, which is reciprocated adjacent to the reel H6 by a double thread screw I52 mounted rotatably in bearings I53I 53 carried by the reel supporting frame 94. The screw I52 is rotated insynchronization with the variable rate of rotation of the reel II6 by a friction disc I55 keyed to the screw I52 and bearing against the periphery of the disc II2 so that the cordage is distributed upon the takeup reel I I6 uniformly.

A shoe I56 carried on an arm I51 gently price the cordage I6 away from the mandrel I4 as the shoe is revolved around the mandrel I4 with the frame I0. The arm I5! is secured rigidly to a bevelled gear I58 meshing with a bevelled gear I59 fixed to a feeler I60. I59 are mounted on and are revolved with the frame I0 by a suitable mount I6I secured to the frame Ill. The gear I58 is rigidly secured toa shaft I65 carried on the mount I6I, and a torsion spring I66 tends to rotate the shaft I65 so as to bias the arm I51 and, in consequence, the shoe I56 toward the mandrel I4. Normally, the spring-biased arm I51 holds the shoe I56 lightly against the mandrel I4 but as one'of the straightening discs 26-26 approaches the shoe, that disc strikes the feeler I66 and moves the feeler I60 out of its path. The movement of the feeler I66 turns the shoe I56 through the gears I56 and I59 against the force of the torsion spring I66 and out of the path of the disc, which is advanced therepast. As the disc clears the shoe I56, the .disc moves out of contact with the feeler I69 and the shoe is moved back into engagement with the mandrel I4 by the torsion spring I66.

The cordage I0 is temporarily straightened slightly as it is gently pried from the mandrel I4 and passes through a guide passage I62 (Fig. 6) and a guide ring I53 formed in the shoe I56, after which the tightly coiled portions of the cordage recoil into tight helices. The shoe I56 is provided with a concave portion I65, which normally rests on the mandrel I4. The concave portion I65 of the shoe I56 joins an adjacent curved surface I68 to form a wedge-like edge I69. Since the frame I0 is rotated about the mandrel I4 and the shoe I56 is carried by the frame I6,

the shoe I56 is rotated about the mandrel I4 as the mandrel is advanced therepast. As a result of the longitudinal movement of the mandrel I4 and the rotation of the shoe I56 about the mov ing mandrel, the wedge-like edge I69 is forced between the mandrel and the successive advancing convolutions of the helically wound cordage The gears I58 and 6 I0, and the cordage is thereby pried away from the mandrel. As the cordage is unwound from the mandrel I4, the unwinding tends to twist the cordage at 5 the rate of one turn per revolution of the reel I I6 around the mandrel II4. This twist is immediately removed from the coiled cordage by the revolution of the reel H6 and the cordage feeder I23 by the shaft 95, which untwists the cordage at the rate of a single turn per revolution of the reel I I6 so that the uncoiling operation does not affect the axial twist of the helically coiled cordage.

Operation In the operation of the apparatus described hereinabove, the flexible mandrel I4 carrying the straightening discs 2626 (Fig. 1) is advanced continuously at a uniform rate of speed through the coiler I5, the oven 20 and the uncoiler 2|. The coiler I5 coils the cordage I0 into a series of close helices upon the portions offlexible mandrel I4 between the discs 26-46 and applies any desired twist to the cordage to form a loose helix or a tight helix whichever is wanted. The coiler applies the cordage to each of the discs 2626 in two substantially straight portions.

The oven 26 softens the plastic elements of the cordage in the forms in the helices and straight portions, and the plastic elements cool to set in those forms. The uncoiler 2I is continuously rotated around the mandrel I4 in a counterclockwise direction, as viewed in Fig. 5. As the uncoiler 2! is rotated, the shoe I56 is revolved around the mandrel and the wedge-like edge E69 from the mandrel and is forced through the passage I62 and the guide I63 by the shoe I56. The

cordage reassumes its set shape as it passes through the shoe I56, and is advanced toward the take-up reel II6 by the feeder I23 at the same rate at which it is uncoiled from the mandrel I4.

The portion of the cordage uncoiledfrom the mandrel I4 is rotated around its own. axis by the feeder I23 as the feeder is revolved by the supporting frame 94 so as to take out any twist imparted to the coiled cordage by uncoiling it from the flexible mandrel I4. The distributor I59 distributes the cordage in close turns upon the taker up reel H6 in synchronization with the rate at which the reel I I 6 is rotated, which rate is varied under the control of the feeler I20 to keep the rate at which the take-up reel I I6 coils the cordage thereon the same as that at which the cordage is fed thereto by the feeder I23. The feeder advances the cordage towards the take-up reel I I6 at the same rate at which it is uncoiled from the mandrel II4 so that there is only sufficient tension upon the coiled portion of the cordage of the shoe gently pries and wedges the cordage I0 from the mandrel and discs 2626, tempo 7 apparatus serve to uncoil temporarilyi cordage and take it up in recoiled form with all the twist efiect. inherently imparted to the cordage from the uncoiling operation taken out of the cordage.

Whatis claimed is:

1. An apparatus for making retractile cordage, which comprises a-generally cylindrical, elongated mandrel having a plurality of disc-like protuberances spaced at equal intervals along a substantial length thereof, means for coiling cordage helically upon the mandrel at a predetermined rate of speed, means for actuating the cordage coiling means, and means for advancing the mandrel and the disc-like protuberances through the cordage coiling means at a predetermined rate of speed, wher.eby cordage coiled upon the mandrel. by the coiling means. is formed on the mandrel in a series of helical portions spaced apart by short, substantially straight portions.

2. An apparatus for making continuous retractile cordage, which comprises an endless mandrel having a predetermined diameter, a plurality of discs mounted on the mandrel at equally spaced points thereon which discs are larger in diameter than the mandrel, a serving head for applying cordage to the mandrel, means for rotating the serving head about the mandrel to coil cordage carried thereby helically upon the mandrel, and means for advancing the mandrel and the discs through the serving head.

3. An apparatus for making continuous retractile cordage, which comprises an endless, flexible mandrel having a predetermined diameter, a plurality of discs mounted on the mandrel at equally spaced points which discs are larger in diameter than the mandrel, a serving head for applying cordage to the mandrel, means for rotating the serving head about the mandrel to c'oil the cordage helically upon the mandrel, and means for engaging the discs to advance the mandrel and the discs through the serving head.

4. An apparatus for making retractile cordage, which comprises an elongated mandrel having a predetermined diameter, a plurality of discs having a diameter substantially larger than that of the mandrel mounted on the mandrel coaxially therewith at spaced points therealong,a serving head for serving cordage on the mandrel, means for advancing the mandrel and the discs through the serving head at a uniform rate of speed, and means for revolving the serving head around the mandrel and the discs at a uniform rate of speed, whereby cordage coiled upon the mandrel and the discs by the serving head is formed into a seriesof helices on the portions of the mandrel between the discs and substantially straight portions between the helices at the. points where the discs are located.

5. An apparatus for making continuous retractile cordage, which comprises an endless, flex- .ible mandrel, means for continuously advancing the mandrel along a predetermined path, a plurality of discs carried by the mandrel coaxially with respect to the mandrel at spaced points therealong, a serving head for continuously serving cordage upon the mandrel and the discs carried thereby, whereby the cordage is coiled into a series of helices separated substantially by straight portions, means for rotating the serving head, means surrounding a portion of said path of cordage served by the serving head on the mandrel and the discs, and means revolvablearound the mandrel for continuously 83', unwinding. the: cordage. from the mandrel and the discs;

6. An. apparatus for making continuous: retractile cordage from cordage including an element of plastic material, which comprises an elongated mandrel, a plurality of. discs having a diameter substantially larger than that of the mandrel carried by the mandrel at equally spaced points thereon, means for advancing the mandrel and. the discs along a predetermined path, a serving, head, means for rotating the serving head about the mandrel and the discs to serve suchcordage thereon, means positioned along said path. for heating cordage so served, a take up reel, means for revolving the take-up reel around the path to unwind the cordagev from the mandrel and the discs, a shoe revolvable with the take-up reel for prying the cordage fromthe mandrel, means for urging the shoe toward the mandrehand means operable by one of the discs as that discapproaches the shoe for moving the shoe against the action of the shoe-urging means out of the path of the disc.

7-. An apparatus for making continuous retractile cordage from cordage including an element made of plastic material, which comprises an elongated mandrel, a plurality of discs of greater diameter than the mandrel positioned on the mandrel at equally spaced. points therealong, meansfor advancing the mandrel and the discs along a predetermined path, a'serving head, means for rotating the serving head about the path of the mandrel to serve such cordage helically on the mandrel and over the discs, means positioned along said path for heating cordage so served, a take-up reel, means for revolving the take-up reel around the path to unwind the cordage from the mandrel and the discs, a pivoted arm revolvable with the take-up reel, a shoe carried by the arm for prying the cordage from the mandrel, means for urging the arm toward the mandrel, and means operable by one of the discs as that disc approaches the shoe for moving the arm against the action of the arm-urging means to move the shoe outo the path of the disc.

8. An apparatus for making continuous re'- tractile cordage, which comprises an elongated mandrel having a predetermined diameter, a plurality of discs having a diameter substantially larger than that of the mandrel and; fastened to the mandrel at points along the mandrel spaced equal predetermined distances apart, a serving head for serving cordageupon the mandrel and the discs, means for advancing the mandrel and the discs through the serving head at a uniform rate of speed, and means for revolv ing the serving head around the mandrel and the discs at a uniform rate of speed.

9. An apparatus for making continuous re tractile cordage, which comprises an elongated mandrel, a plurality of washers mounted co axially on the mandrel at points spaced equidistantly on the mandrel, means for advancing the mandrel and the washers along a predetermined path at auniform rate of speed, means rotatable about said path for serving cordage upon the mandrel and the washers and means for rotating the cordage serving means.

10. An apparatus for making continuous retractile cordage, which comprises an elongated mandrel, a plurality of washers carried by'the' mandrel at points spaced equidistantly there'- along, means for advancing the mandrel and the washers along a predetermined path, a serving head rotatable about said path for coiling cordage up on the mandrel and the washer, means for rotating the serving head, and a retractible guide carried by the serving head for normally engaging the mandrel but permitting the discs to be advanced therepast.

11. Aiiiapparatus for makingcontinuous retractile; cordage, which comprigesan elongated mandrel, a plurality of washers carried by the mandrel at pointsspaced eqfiiidist'antly therealong, means for advancing the mandrel along a predetermined path, a serving head rotatable about a portion of said path for serving cordage on the/mandrel means for rotating the serving head and the washers, and a'j air of escapement guides carried by the serving head for engaging ,th'e' mandrel to preventglateral deflection thereofilland movable out of engagement with the mandrel by the washers, saidgguides being spacedalong the path of the mandrel sufiiciently far apart to permit only one of the,,,guides to be moved by a washer away from the mandrel at any instant. 3

12. An apparatus for making continuous retractile cordage, which comprises an elongated mandreha plurality of discs carriedby the mandrel at'fpoints spaced equidistantly therealong, a serving head for serving cordage on the mandrel and the washers, means for rotating the servingl head means for advancing the mandrel through the serving head, a forked: guide carried pivotally by the serving headfafid means for urging the guide into engagement with the mandrel and for permitting one of the" discs to move the guide away from the mandrel.

13. An apparatus for making retractile cordage,,[which comprises a generally cylindrical, elongated mandrel having a plurality of disclilge protuberances spaced at equal intervals along a; substantial length thereof, a serving head revolvable about the mandrel for simultaneously twisting cordage longitudinallyfand coiling the cordage helically upon the mandrel, means for revolving the serving head, and means for advancfing the mandrel and the disc-like protuberances. through the serving head, whereby longitudinally twisted cordage is coiled upon the mandrel Sin the form of a series of helical portions spaced apart by short, substantially straight portions.

WILLIAM L. AMES.

REFERENCES CIT D The following references are of record in the file of this patent: V

UNITED STATES PATENTS Number Name Date 1,498,845 Lakin June 24, 1924 2,365,952 Hanson Dec. 26, 1944 2,375,357 Friedman May 8, 1945 2,394,762 Geraty Feb. 12, 1946 2,424,426 Arnold July 22, 1947 

